4.4% fuel and 88% makeup water daily savings for a beverage MNC in Indonesia

Issues faced recovering condensate from their hot water generator (HWG) and clean-in-place (CIP) system.

Condensate recovery factor was 23%. Significant loss of heat energy seen, raising costs.

Forbes Marshall recommended and implemented the following thermal energy conservation solutions in the plant:

• A steam operated pump trap (SOPT- LH) was installed to eliminate condensate stalling.
• A steam-operated pressure-powered pump (PPPPU) was installed for condensate recovery.
• A condensate recovery meter was installed to measure totalised flow, temperature, energy and fuel savings.

Average daily fuel consumption reduced from 2040 to 1949 cubic meter (539K to 515K Gallons) i.e. a 4.4% reduction

Condensate recovery factor increased from 23% to 91%

Daily makeup water consumption reduced from 19,010 to 2,250 cubic meter (5022K to 594K Gallons) i.e. an 88% reduction

Daily Water savings of 16.76 Tonnes (4428 Gallons)

Daily energy savings of 3866 MJ (3.66 MMBtu)

Annual monetary savings of USD 14,089 (~IDR 234,285,981 *converted based on exchange rates)